Pile fabrics and method of making the same



Patented Jan. 13, 1931 UNITED STAT-ES ALBERT W. DROBILE, OI CYNWYD, IPEN-NSYLVANIA FILE FABRICS AND METHOD OF MAKING THE SAME Io Drawing. Application filed April 8,

My invention is an improved pile fabric having the loops of the pile united to the backing fabric by the solidified pliable composition resulting from the coagulation in situ on the backing of an aqueous colloidal dispersion of previously uncoagulated rubber which, by reason of its affinity for the fibres and the capillary actions thereof, intimately permeates the fibres of the backing and pile and forms a bond between them quite different from and superior to the effect of coating pile fabrics with organic solutions of rubber and other non-aqueous substances heretofore proposed for use in coating pile fabrics. In the preferred embodiment of my invention, the aqueous dis persion of rubber contains vulcanizing-substances preferablyin colloidal form, which are carried into the pores of the fibres and facilitate the coagulation or "vulcanization of the rubber in such pores as well as in the interstices between the fibres so that the pile is embedded in a substantially continuous film which not only firmly anchors the pile and reenforces the backing but tends to render the fabric impervious to moisture without detracting from the appearance or feel of the fabric or of the pile thereof. The composition is insoluble in water after solidification, and may be colored or embossed to. give desired effects independently of or in conjunction with pile decoration resulting from printing, cutting, singeing, acid treat-v ment or the like. The aqueous dispersions of rubber which I have found most suitable for use on pile fabrics contain vulcanizing agents, such as colloidal sulphur, zinc oxide and an accelerator, and these constituents may either be retained inert in the aqueous rubber until after coatingis completed, or they may be permitted to vulcanize, without coagulating, the rubber before coating the fabric.

When a prevulcanized coating is used, the

- film is set by the evaporation of the watery constituent of the coating, which is preferably done bythe application of a moderate drying heat or a vacuum, which causes the coagulation of the rubber content it an impervious film intimately permeat- 1929. Serial No. 353,660.

ing the backing and a desired portion of the pile. When an unvulcanized coating contaming vulcanlzers is used, the coated fabric is preferably sub ected to .a vulcanlzing heat,

which both vulcanizes and 'coagulates the and held firmly in even a tightly woven backing without being secured b backing picks or being floated in the bac in By the utilization of my improvements t e pile is firmly embedded regardless of the looseness of the backing or the resiliency of the pile fibres,-and' the loose backing is filled or weighted by the film deposited in the pores ofthe fibres thereof so as to give the feel and wear of a closely wo'ven backing, and the pile may be closely cut to form a very short nap without causing shedding, despite the fact that each pile is" looped over but a single pick.

By the practice'of my invention, a pile fabric may be inexpensively woven with a dense face of animal fibres, such as mohair, looped around each .pick or weft threadwithout floating the pile warps in thebacking or anchoring them by locking picks. Such fabrics, particularly when the piles are cut short 'or the wefts are lightly beaten up are unsuitable for the use to which the fabrics are to be put but are rendered suitable for such use and given greater durability than usual pile fabrics by uniting the pile loops. and backing threads in av continuous film resulting from coating on the back of the fabric an aqueous dispersion of rubber containing a vulcanizer and accelerator which is drawn into intimate relation with the fibres by the capillary action thereof upon. the coating.

The coating composition is preferably gradually fed'to the backing fabric adjacent to a knife or scraper by which it is evenly spread over the surface, but may be applied in any suitable manner, and either after or before the pile has been split to separate the double backings. After coating, the

fabric is preferably immediately subjected after dying to prevent such bleeding may be eliminated. i

The fabrics produced may be decorated by cutting, singeing, embossing or acid treat-' ment in any usual way.

Having described my invention, I claim: 1. An improved pile fabric having loops of the pile containing animal fibre united to the backing fabric by a solidified pliable composition resulting from the coagulation in situ on the backing'of an aqueous dispersion of rubber permeating the interstices of said fabric.

2. An improved pile. fabric having loops of the pile containing animal fibre united to the backing fabric of predyed yarn by a solidified pliable composition resulting from the coagulation in situ on the backing of an aqueous colloidal dispersion of previously uncoagulated rubber and a vulcanizer.

3. An improved pile fabric comprising a backing of predyed yarn containing resilient pile warps containing animal fibre and .too loosely bound by said backing to alone securely hold said warp threads for the use to which the fabric is to be put and a film capillarily permeating said backing and pile warp and consisting of a pre- 'viously uncoagulated aqueous dispersion of rubber and said pile containing dye uncontaminated by bleeding from said predyed yarn.

4. The method of making pile fabric which comprises weaving a loose textile backing of predyed threads with pile warps containing animal fibre loosely looped over the picks of said backing and permeating said backing and pile loops by capillary action with an applied to sai acking opposite the'pile.

-5. The method of making pile fabric which comprises weaving a. loose textile backing with resilient pile warps containin 1 animal fibre loosely looped over wefts of sai backing and permeating said backingand pile loops by capillary action with an'aque- -0l1S diSpe1S10Il of rubber containing a vulaqpeous dispersion of rubber (1 canizing agent and'vulcanizing said rubber in situ. I

6. The method of making pile fabric which comprises weaving a loose textile backing of predyed yarn with resilient pile warps containing animal fibre and loosely looped therein and. permeating said backing and pile'loops by capillary action with an aqueous dispersion of rubber containing an emulsifying agent and an accelerator.

7. The method of making pile fabric which comprises weaving a loose textile backing with pile warps containing animal fibre loosely looped therein, permeating said backing and pile loops by capillary action with an equeous dispersion of rubber, coagulating said rubber by heat, and dying and finished the coated fabric.

8. The method of making pile fabric which comprises weaving a loose textile backing from previously dyed bacln'ng threads and looping pile warps containing animal fibre loosely over wefts of said backing, permeating said backing and pile loops by capillary action with an aqueous dispersion of rubber containing a vulcanizer, coagulating said rubber, and face-dying said fabric.

In testimony whereof I have hereunto set my hand this sixth day of April, 1929.

ALBERT W. DROBILE. 

